Highly reflective mounting arrangement for LEDs

ABSTRACT

A semiconductor device emitting light about a predetermined wavelength comprising a structure comprising a plurality of layers, sometimes referred to as a stack, providing low resistance, high reflectivity and ohmic contacts to at least one semiconductor material.

PRIORITY

This application is a continuation of U.S. Ser. No. 11/378,763, filed onMar. 17, 2006 and claims priority there from.

CROSS REFERENCE TO RELATED DOCUMENTS

The present invention is related in part to application Ser. Nos.11/296,006, “Light Emitter with Metal-oxide Coating” and 11/378,763,assigned to the same assignee, incorporated herein in their entirety byreference.

FIELD OF THE INVENTION

This invention relates to a reflective submount for light emittingdevices (LEDs).

BACKGROUND OF INVENTION

Light emitting devices (LEDs) emit light in response to excitation by anelectrical current. One typical LED includes a heterostructure grown ona substrate by metal-organic vapor phase epitaxy or similar techniques.A LED heterostructure includes n and p type semiconductor layers thatsandwich light producing layers. Exemplary light producing layers may bequantum wells surrounded by barrier layers. Typically, electricalcontacts are attached to n and p semiconductor cladding layers. When aforward bias is applied across electrical contacts electrons and holesflow from n and p layers into a light producing active region. Light isproduced when these electrons and holes recombine with each other in anactive region comprising at least one semiconductor material.

The efficiency with which a LED converts electricity to light isdetermined by the product of the internal quantum efficiency, thelight-extraction efficiency, and losses due to electrical resistance;this product is also termed the external quantum efficiency. Theinternal quantum efficiency is determined by the quality of thesemiconductor layers and the energy band structure of the device. Bothof these are determined during deposition of semiconductor layers. Thelight extraction efficiency is the ratio of the light that leaves theLED chip to the light that is generated within the active layers. Thelight extraction efficiency is determined by the geometry of the LED,self-absorption of light in semiconductor layers, light absorption byelectrical contacts, and light absorption by materials in contact withthe LED that are used to mount a device in a package. Semiconductorlayers have relatively high indexes of refraction; consequently, mostlight that is generated in an active region is internally-reflected bysurfaces of a chip many times before it escapes. To achieve highlight-extraction efficiency it is important to minimize absorption oflight by the semiconductor layers and by electrical connections to thechip. When these layers are made to have very low optical absorption, bybeing transparent or highly reflective, the overall light extraction inan LED is improved substantially.

When an LED is energized, light emits from its active layer in alldirections, impinging on the LED surfaces at many different angles.Typical semiconductor materials have a high index of refraction comparedto ambient air, n=1.0, or encapsulating epoxy, n≈1.5. According toSnell's law, light traveling from a material having an index ofrefraction, n₁, to a material with a lower index of refraction, n₂, atan angle less than a certain critical angle θ_(c) relative to thesurface normal direction will cross to the lower index region, whereθ_(C)=sin⁻¹(n ₂ /n ₁)  (1)

Light that reaches a semiconductor surface at angles greater than θ_(C)will experience total internal reflection. This light is reflected backinto the LED chip where it can be absorbed within the chip or in metalcontact layers that are attached to the chip. For conventional LEDs, thevast majority of light generated within the structure suffers totalinternal reflection at least once before escaping from a semiconductorchip. In the case of conventional GaN-based LEDs on sapphire substratesabout 70% of emitted light is trapped between the sapphire substrate andthe outer surface of the GaN. This light is repeatedly reflected,greatly increasing its chance for reabsorption and loss.

Several prior art approaches have been used to create reflective ohmiccontacts for LEDs. The simplest is to use a thick sheet or layer ofmetal that has a high reflectivity. These include Al, Ag, Rh, Pd, Cu,Au, Cr, Ti, Ni, nickel/gold alloys, chrome/gold alloys, silver/aluminummixtures, combinations of the preceding and others known to one familiarwith the art. The chosen metal needs to not only have a highreflectance, but also make a low resistance ohmic contact. In the caseof p-type AlInGaN, only Ag combines low electrical resistance with highreflectivity. Unfortunately, Ag presents a reliability concern becauseit is subject to tarnish and it is subject to electromigration duringdevice operation. Also, the contact resistance of Ag-based contactssometimes increases with time during device operation.

Wierer, et al., WO 01/47038 and U.S. Pat. No. 6,992,334, disclosed amulti-layer contact with one metal to make the ohmic connection to thedevice and a second metal to provide high reflectivity. The first metalmay be a low reflectance metal because it is kept very thin, less than20 nm, so that light penetrates through to the more reflective layer.The more reflective metal may be very thick to spread currenteffectively across the chip. The reflectivity of the combined metalstack can exceed 75%. However, these contacts are still too absorptiveto achieve very high light-extraction because the reflectance of metalsis limited to below about 93%; in addition, metals suitable for formingan ohmic contact are highly absorbing.

Schubert in U.S. Pat. No. 6,784,462 and in Applied Physics Letters, 84,22, 31 May 2004, 4508, disclosed a reflective submount for an LED thatinterposed a dielectric layer under a portion of the metal contact toimprove the overall reflectivity. In this scheme a plurality of ohmiccontacts are made to the semiconductor using metal vias through thedielectric layer. The metal in these vias makes contact to spots on thesemiconductor and a semiconductor layer spreads current between thespots. Schubert teaches a dielectric with a thickness chosen to be aboutone-quarter of a wavelength. This single dielectric layer serves toimprove the reflectance compared to a simple metal reflector, but itdoes not provide for high reflectance for light incident at high angles,since the dielectric is so thin. The contact area to the semiconductoris small for these contacts which can significantly increase theresistance to electrical current flow, reducing the overall efficiencyof the LED. Also, since the electrical contact is made in spots thecurrent injection is not uniform over the surface of the chip. In theApplied Physics publication Schubert teaches that the “ . . .micro-contact array covers only about 2% of the entire back side litarea of the LED chip.” Schubert in Applied Physics Letters, 87, 031111(2005), discloses an “omni-directional reflector” realized by thecombination of total internal reflection using a low-refractive-indexmaterial and reflection from a one-dimensional photonic crystal. Thelow-refractive-index material is nanoporous SiO₂ with an index ofrefraction about 1.1; Schubert notes that n must be below 1.112 or thereflectivity falls off sharply. The one-dimensional photonic crystalstructure is achieved with four pairs of very thin films of TiO₂ andSiO₂ with a very narrow tolerance on each film thickness. Schubert'sdata indicates quite good reflectivity; however the process he teachesis complex and has quite tight tolerances requiring very expensiveprocess controls; low yields can be anticipated.

Dielectric Bragg reflectors, DBRs, have been disclosed in U.S. Pat. No.6,552,369 wherein an epitaxially grown AlGaAs/AlInGaP structure istaught. In U.S. Pat. No. 5,585,648 the device comprises a SiC substratewith an optional DBR made from AlInGaN. U.S. Pat. No. 6,492,661 teachesa refection layer with a current blocking region; U.S. Pat. No.6,492,661 also teaches substitution of an alternative substrate for anoriginal substrate after device fabrication. U.S. Pat. No. 6,797,987teaches a transparent, electrically-conductive oxide layer over coatedwith reflective layer; a substitute substrate replaces the originalsubstrate; no oxide layer or Bragg reflector layer is taught.

Therefore a need exists for a reflector structure that provides forlow-resistance contacts and conduction across a device while at the sametime providing for high reflectance of light incident at all angles andcan be manufactured in high volumes at low cost.

SUMMARY OF THE INVENTION

The instant invention discloses a reflective structure comprising aplurality of layers, sometimes referred to as a reflective stack,providing in various embodiments various combinations of low opticalloss, high reflectivity, ohmic contacts and low manufacturing cost. Insome embodiments a first, optically transmissive layer providing goodohmic contact across the device is deposited onto a semiconductorcladding layer and annealed, optionally. In an embodiment a first layer,comprising indium-tin oxide, ITO, makes ohmic contact to a semiconductorlayer; the layer has high optical transmission for the wavelengths ofinterest with very low optical loss. Alternatives to ITO are Ni/Au andRuO₂ compositions. Next an optically transmissive, low-index ofrefraction, dielectric layer is deposited on the transmissive, ohmiccontact layer. This dielectric layer may be made from SiO, SiO₂ or MgF₂,or another suitable dielectric known to one knowledgeable in the art.The dielectric layer provides for total internal reflection of lightthat is incident at high angles, angles far from the surface normal.Contrary to Schubert's teaching, this dielectric layer should be morethan a quarter wavelength of the emitted light in the dielectric medium,preferably at least a half or, more preferably, three quarters of awavelength or greater, so that the evanescent wave from incident lightdoes not penetrate through it. Contrary to Schubert's alternativeembodiment this dielectric layer may have an index of refraction greaterthan 1.12. Next, optionally, a dielectric, distributed Bragg reflector,DBR, is deposited. The DBR comprises alternating layers of highrefractive and low refractive index films. The approximate thicknessesof each of the DBR layers is either mλ/(4*n_(H)) or kλ/(4*n_(L)); whereλ is the nominal wavelength of emitted light in air, n_(H) is the indexof refraction of the high index dielectric layer, n_(L) is the index ofrefraction of the lower index dielectric layer and m and k are oddintegers, preferably 1 or 3. The DBR need have only two pairs of thehigh and low refractive index films. The purpose of the DBR is toprovide very high reflectance to light at angles near the surfacenormal. Next a metal layer is provided that makes contact with the ITOlayer using a plurality of vias through the DBR and first dielectriclayer. The metal layer has a reflectivity greater than 50% andpreferably greater than 60% and is used to connect the ITO contact to aLED's substrate or submount. The area consumed by the vias should be assmall as possible while providing for low resistance access to the ITO.The metal may contribute to the reflectance of the entire stack.

In an alternative embodiment a low resistance, high reflectivity, ohmiccontact stack includes a transparent ITO contact, a thick, low index ofrefraction dielectric and a reflective metal with vias to the ITOcontact; in this embodiment there is no dielectric DBR. In analternative embodiment a low resistance, high reflectivity, ohmiccontact stack also includes a last solderable metal layer such as AuSnfor making contact to a submount, substrate, or an LED package. Asolderable metal layer may comprise other layers such as Ni, Pt, TaN,TiWN or others known to one knowledgeable in the art that preventmigration of a solder layer to a stack structure.

In an alternative embodiment a thick, low index of refractiondielectric, a DBR and a reflective metal stack is deposited on thebottom of the original substrate onto which the LED layers are grown onthe other surface. This structure improves the overall device lightemission at the lowest possible additional manufacturing cost.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a low resistance, high reflectivity,ohmic contact stack embodiment of the present invention.

FIG. 2 illustrates the simulated effect of a relatively thick, low-indexdielectric material on the reflectivity of a metallic reflector.

FIG. 3 illustrates the effect of both a relatively thick low-indexmaterial and a two pair TiO₂/SiO₂ DBR layer on the reflectivity of ametallic reflector.

FIG. 4 is an LED incorporating one embodiment of the instant invention.

FIG. 5 is an alternative LED device structure that includes the instantinvention.

FIG. 6 is an alternative device emitting light structure comprising theinstant invention under a sapphire substrate.

FIG. 7 is an alternative device emitting light structure comprising theinstant invention wherein one or more top layers of metal oxide,optionally, have a predetermined shape and pattern.

DETAILED DESCRIPTION

The present invention is a multi-layer arrangement which providesdistinctive improvements over the prior art including, but not limitedto, ohmic contacts to an LED, providing high reflectivity for light atall angles, low and, preferably, uniform contact resistance, andimproved reliability. FIG. 1 shows a cross-sectional view of oneembodiment of the present invention. In particular, FIG. 1 illustrates astack structure to make ohmic connection to p-type AlInGaN alloys; oneembodiment of LED semiconductor layers are shown in FIG. 4. A multilayerstructure 10 includes a transparent, ohmic contact layer 12 for making alow-resistance, uniform contact to a p-type semiconductor material, forexample AlInGaN. One example of a transparent, ohmic contact layer 12 isITO, commonly formed by electron beam evaporation and preferably in therange of 50-400 nm thick. The thickness of a transparent, ohmic contactlayer 12 is chosen to be sufficiently thick to provide forlow-resistance between metallized vias, but thin enough to minimizeoptical absorption in the layer. An ITO layer may be annealed atelevated temperatures, in a predetermined ambient to improve itstransparency and conductivity and reduce the electrical resistance ofthe contact to a AlInGaN or other semiconductor layer. Additional layersof a multi-layer stack structure are designed to make a reflectiveconnection between a transparent contact and a substrate or submount onwhich a LED is attached. Transmissive contact layer 12 may be of indiumtin oxide, ITO; alternatively, a transmissive contact layer may be ofnickel/gold (Ni/Au) alloys, In₂O₃, SnO₂, CdO, ZnO, CuAlO₂, CuGaO₂,SrCuO₂ or other compositions having high light transmission and ohmiccontact properties known to one knowledgeable in the art.

As shown in FIG. 1, a next layer of a multi-layer stack structure is adielectric layer 14 formed on ITO. In one embodiment a dielectric isSiO₂ deposited by electron beam evaporation, sputtering, plasma-enhancedchemical vapor deposition, spin-on glass or other methods known to oneknowledgeable in the art. In a preferred embodiment, the thickness of adielectric is in the range from 50-700 nm. More preferably, thethickness is several times thicker than λ/4n where λ is the nominalwavelength emitted by the LED in air and n is the refractive index ofthe dielectric layer, for instance, SiO₂. Unlike the teachings ofSchubert, U.S. Pat. No. 6,784,462, the instant invention's dielectriclayer is purposely of a thickness such that light incident on amultilayer stack at glancing angles will not penetrate through thedielectric layer; instead, light emitted through an ohmic contact layerundergoes total internal reflection and is reflected back into a LEDlight emitting portion structure with minimal loss. Materials other thanSiO₂ may be used for a second stack layer provided they absorb minimallight from a LED; more preferably, a material for a second layer has alow index of refraction; an ideal material for a second stack layer isalso a good heat conductor; this combination of properties is difficultto achieve in practice; engineering trade-offs must be made.

In one embodiment, an optional next layer in a multi-layer stackstructure is a dielectric distributed Bragg reflector, DBR, 16, formedadjacent to dielectric layer, 14, using a combination of high and lowrefractive index materials. It is preferred that the two materialschosen have indexes of refraction that are as different as possible tomaximize the reflectivity of a stack over all angles. Chosen materialsshould have also very low absorption at the wavelength emitted by theLED. In one preferred embodiment a high-index material is TiO₂ and alower index material is SiO₂. Materials suitable for high index layersare titanium dioxide (TiO₂), Ti₃O₅, Ti₂O₃, TiO, ZrO₂+TiO₂ZrO₂Nb₂O₅,CeO₂, ZnS₅ Al₂O₃, niobium pentoxide (Nb₂O₅) and tantalum pentoxide(Ta₂O₅). Low index materials are SiO, SiO₂, and MgF₂; in someembodiments low and/or high refraction index materials may be polymerssuch as siloxane polymers or others known to one knowledgeable in theart. The thicknesses of DBR layers, preferably, are odd multiples ofquarter wavelengths as previously described. The DBR materials arearranged such that a high index material is next to layer 14, the thick,low-index dielectric. In a preferred embodiment a two layer combination,or pair, of high n_(H)/low n_(L) index of refraction materials isrepeated at least twice giving a four layer structure of high n_(H)/lown_(L)/high n_(H)/low n_(L). In the embodiment shown in FIG. 1 two pairs,16, are shown; in many embodiments two pairs are sufficient to achievevery high reflectivity over all angles. Increasing the number of pairsabove two marginally improves the reflectivity, but increases thecomplexity and cost of a LED. DBR layers may be deposited usingevaporation, physical vapor deposition, atomic layer deposition, ALD, orother well known techniques.

A next layer in a multi-layer stack structure is a metallic layer 18,positioned adjacent to a DBR in this embodiment or next to a dielectriclayer should a DBR not be present. Metallic layer 18 is preferably madefrom a material that has high reflectivity such as aluminum or silverand is sufficiently thick so that light cannot penetrate. A plurality ofreflective metal filled vias 20 are provided through DBR and dielectriclayers so that a metal can make contact to ohmic contact layer 12. Theportion of a multi-layer stack structure comprising vias will have lowerreflectance than a region absent vias. To achieve high overallreflectivity the area of vias should be kept to a small fraction of thetotal area, preferably less than 10%. Spacing between vias is determinedby the electrical conductivity of an ITO or other ohmic contacting andtransmissive layer 12, which spreads a current preferably uniformlyacross a light emitting surface.

FIGS. 2 and 3 illustrate how various portions of a multilayer stackcombine to provide for high reflectance. FIG. 2 is a calculation thatshows the improvement in reflectivity of a metal contact by including athick, low-index dielectric layer 14, such as the SiO₂ in FIG. 1. Thesecalculations show the reflectance of light incident from ITO-coated GaNwith an aluminum reflector 231. This is compared to the case 233 where aquarter wavelength layer of SiO₂ (800 angstroms) is between the ITO andthe aluminum reflector, as taught by Schubert. Also shown is thereflectance for the case 235 where the SiO₂ layer is thick, in this case5,000 angstroms. The reflectance is shown as a function of the angle ofincidence of the light, where 0 degrees is normal incidence. An aluminumlayer directly on ITO, curve 231, provides a reflectance of about 84%for light at normal incidence, falling off to about 67% at 78° beforerecovering to about 100% at 90°. The reflectance of a simple Alreflector being below 70% near 80 degrees, is undesirably low. Theaddition of a ¼ wavelength thick SiO₂ layer, curve 233, improves thenormal angle reflectance to about 88% at normal incidence and more than90% for angles larger than 47 degrees. However, the reflectance is stillonly about 70% for light incident at 40 degrees from normal incidence.This is because the evanescent wave “sees” through the SiO₂ to thealuminum. Also shown in FIG. 2 is one embodiment of the instantinvention, curve 235, indicating the reflectance of a thick, 5,000angstrom, SiO₂ layer between GaN and aluminum. In this embodiment of theinstant invention the light undergoes almost total internal reflectance(TIR) at angles greater than about 40 degrees, such that the lightsuffers only minor absorption in the ITO or other conductive contactlayer. In this embodiment the reflectance is more than 95% for allangles greater than 35 degrees. Also, the reflectance remains above 80%for all angles in distinct contrast to the prior art and teaching. ForLEDs made according to instant invention embodiments with anappropriately chosen thickness dielectric layer, significantly improvedextraction efficiencies are obtained.

FIG. 3 illustrates how an appropriately chosen thickness dielectriclayer can be combined with a dielectric DBR stack to further improveemitted light reflectance at angles near normal incidence. By includinga two pair TiO₂/SiO₂ DBR emitted light reflectance 337 is increased toabout 97% between 0 and 20 degrees. Emitted light reflectance drops toas low as 85% at angles around 34 degrees then increases again at higherangles due to TIR. Averaged over all angles, emitted light reflectance337 of this embodiment of the instant invention multilayer stack is farsuperior to previously disclosed prior art, while providing for a lowresistance ohmic contact using a transparent conductive layer,optionally, ITO. Since light within a LED may strike a contactingarrangement many times before escaping a LED structure, the instantinvention contacting layer structure described here results in asubstantial increase in overall light extraction.

FIG. 4 shows an exemplary AlInGaN based LED structure 400 mounted usinga multi-layer, reflector ohmic contact stack. A stack, such as shown inFIG. 1, 10, provides for contact to a p-type layer 440. A light emittingportion, comprising 440 and 450, is positioned p-side down on areflective stack 10, comprising layers 20, 12, 14, 16 and 18; stack 10is attached to substrate 430. In one embodiment, reflective stack 10 isattached to substrate by a solder layer, such as AuSn, or other suitablematerial that provides a low resistance contact, not shown. In oneembodiment, electrical connection 470 to a p-contact is provided at abottom of substrate 430. Light incident on a reflector stack isredirected upwards towards a surface of a chip where it escapes. A topsurface of a chip may include textured features, not shown, to preventlight becoming trapped in semiconductor layers. Alternatively, adielectric coating on a top surface of a chip includes features thatscatter light out of trapped modes; these features may be textured in afilm or be photonic crystal structures or other embodiments. A topsurface of a LED has an n-contact 460 that is patterned to distributecurrent evenly across a top surface. Ideally a top contact should alsobe as reflective as possible, at least 50% and preferably more than 60%;top contact 460 can be made from a reflective metal such as aluminum. An-type contact 460 may include a reflective stack similar to ap-contact, but only covering a small portion of a top surface.

FIG. 5 is an alternative embodiment of an LED utilizing a multi-layerreflector stack. In this embodiment access to a p-contact is made byremoving the AlInGaN layers on a portion of a device. In this wayelectrical access to a p-metallization can be made from a top side of achip. An insulating layer is used to provide electrical insulationbetween the semiconductor and the bottom of the substrate. This isdesirable because LEDs can be mounted so that electrical current flow isisolated from the path of heat flow which is through the metallicsubstrate.

FIG. 6 is an alternative embodiment of an LED utilizing a multi-layerreflector stack 8 on a “bottom surface” of an LED device structureincluding a substrate of sapphire or SiC 432. In this embodiment anoptically transmissive, low-index of refraction, dielectric layer isdeposited on the substrate surface opposite the LED active layers. Thisdielectric layer may be made from SiO, SiO₂ or MgF₂, or another suitabledielectric known to one knowledgeable in the art. The dielectric layerprovides for total internal reflection of light that is incident at highangles, angles far from the surface normal. Next, a dielectric,distributed Bragg reflector, DBR, is deposited. The DBR comprisesalternating layers of high refractive and low refractive index films.The approximate thicknesses of each of the DBR layers is eithermλ/(4*n_(H)) or kλ/(4*n_(L)); where λ is the nominal wavelength ofemitted light in air, n_(H) is the index of refraction of the high indexdielectric layer, n_(L) is the index of refraction of the lower indexdielectric layer and m and k are odd integers, preferably 1 or 3. Next ametal layer is provided that has a reflectivity greater than 50% andpreferably greater than 60%; the metal may also comprise a diffusionbarrier layer and a layer of material to facilitate solder attach.Multi-layer stack structure 8 comprises an optically transmissive,low-index of refraction, dielectric layer, a DBR comprising alternatinglayers of high refractive and low refractive index films and a metallayer comprising, optionally, a diffusion barrier layer and a layer ofmaterial to facilitate solder attach.

FIG. 7 is an alternative light emitting device structure comprising theinstant invention wherein one or more top layers of metal oxide 720 havea predetermined shape and pattern; metal conductors 710 provide contactto a n-type semiconductor light emitting portion; contact to a p-typelight emitting portion is made with a transparent, ohmic contact layer12 for making a low-resistance, uniform contact to a p-typesemiconductor material, for example AlInGaN; other light emittingsemiconductor materials are alternative embodiments. Multi-layer stackstructure 10, as shown in FIG. 1 is an embodiment for a reflective stackas shown here; alternative stack embodiments are also possible with ametal-oxide layer also.

A metal-oxide layer in this application preferably comprises one or morelayers wherein at least the first layer has an index of refractiongreater than 2 and an optical extinction coefficient (the imaginaryportion of the index of refraction) less than 0.2. A metal-oxide layeris chosen, preferably, from a group comprising metal oxides, siliconcarbide, GaN, Ta₂O₅, Nb₂O₅, TiO₂, AlInGaN based solid solutions andtheir non-stoichiometric mixtures; optionally, a metal-oxide layerportion has a predetermined shape and pattern that enables a higherlight extraction from a device emitting light.

All primary embodiments of the instant invention rely on a stackcomprising a relatively thick, low-index of refraction dielectric filmof predetermined minimum thickness and a minimum reflectivity metalliclayer. Alternative embodiments comprise, optionally, adding atransmissive, ohmic contact layer and a predetermined number ofalternating dielectric layers of predetermined thickness and index ofrefraction ranges. Light emission from a device emitting light, such asa LED, improves as the complexity of a stack increases; the costincreases as well; the instant invention allows the user to balance alight output requirement against the cost. The teaching of U.S.application Ser. No. 11/296,006 may also be combined with the currentdisclosure to add metal-oxide films, optionally patterned, to a LEDstructure wherein metal-oxide films are deposited and, optionally,shaped and/or patterned on the LED surface not having a reflectivestack, as shown in FIG. 7.

As used herein a substrate or submount portion provides at least a meansfor mechanical support for a light emitting device portion andmetal-oxide coating portion. A substrate is chosen from a groupcomprising Al₂O₃, Si, SiC, AlInGaN based materials, metals, ceramics andglasses; these materials may be single crystal or not. A submount ischosen based on manufacturing convenience; typically a submount ischosen from a group comprising Al₂O₃, Si, SiC, metals, ceramics,plastics and glasses. A substrate comprises greater utility than asubmount, as is well known; both provide a means for at least a thermalconnection to a light emitting portion and in some embodiments either orboth may provide a means for electrical connection to a light emittingportion.

As used herein a device emitting light or light emitting device, LED, ischosen from a group comprising light emitting diodes, light emittingheterojunctions, light emitting quantum well structures and other solidstate devices capable of emitting light. As used herein a light emittingportion of an LED comprises active semiconductor layers or portionsrequired to emit light and surrounding semiconductor layers required forconduction and contact. An original substrate, such as sapphire or SiC,upon which the device is fabricated initially are excluded in thisdefinition. In cases where an initial substrate is removed a replacementsubstrate or submount is required typically for mechanical or handlingor electrical connection purposes to enable an LED to function,optionally, in an “inverted” orientation. A highly reflective, ohmiccontact resistance stack may be added to an LED structure with anoriginal substrate; optionally, a highly reflective, ohmic contactresistance stack may be added to an LED structure as part of a processfor attaching a replacement substrate.

One technique for separating a light emitting device portion from itsoriginal substrate is termed “laser liftoff”. This technique isdescribed in U.S. Pat. No. 6,071,795 and “Laser Liftoff of GalliumNitride from Sapphire Substrates”; Sands, T., et al.; Nov. 18, 2005:http://www.ucop.edu/research/micro/98_(—)99/98_(—)133.pdf. Analternative description is provided by Ambacher, O., et al., “LaserLiftoff and Laser Patterning of Large Free-standing GaN Substrates”;Mat. Res. Soc. Symp., Vol. 617, © 2000 Materials Research Society. Allthree publications are included in their entirety herein by reference.One knowledgeable in the art of silicon on insulator wafer processing isfamiliar with alternative methods for transferring an active layer(s) toanother substrate.

In one embodiment a device capable of emitting light about apredetermined wavelength in response to an applied electric currentcomprises a substrate 432 comprising first and second surfaces; a lightemitting portion, such as 440 and 450 of FIG. 6, comprising asemiconductor material and a first and second surface wherein the lightis emitted from the first and second surfaces and the second surface issubstantially coupled to the first surface of the substrate; a firstlayer coupled to the second surface of the substrate comprising anoptically transmissive, dielectric layer with a refractive index lessthan the refractive index of the substrate and of a thickness greaterthan one-quarter wavelength of the predetermined wavelength divided bythe index of refraction of the optically transmissive dielectric layer;one or more second layers coupled to the first layer wherein each secondlayer comprises a first dielectric layer of high-index of refraction anda second dielectric layer of low-index of refraction wherein the firstdielectric layer is of a thickness about mλ/4n_(H), and the seconddielectric layer is of a thickness about kλ/4n_(L), where m and k areodd integers, X is the predetermined nominal wavelength in air, n_(H) isthe refractive index of the high-index of refraction dielectric layerand n_(L) is the refractive index of the low-index of refractiondielectric layer; and a metallic layer coupled to the one or more secondlayers; wherein the reflectivity of the metallic layer to thepredetermined wavelength is greater than about 50 percent; optionally,the metallic layer comprises at least three layers comprising a firstlayer comprising the metallic layer; a second layer comprising adiffusion barrier; and a third layer of a solderable material; whereinelements of the solderable material are prevented from reaching saidmetallic layer by the second layer; optionally, the opticallytransmissive, dielectric layer is chosen from a group consisting ofsilicon dioxide, silicon monoxide, MgF₂ and siloxane polymers;optionally, the high-index of refraction layer of said one or moresecond layers is chosen from a group comprising titanium dioxide (TiO₂),Ti₃O₅, Ti₂O₃, TiO, [ZrO₂+TiO₂ZrO₂Nb₂O₅], CeO₂, ZnS, Al₂O₃, niobiumpentoxide (Nb₂O₅), tantalum pentoxide (Ta₂O₅) and siloxane polymers andsaid low-index of refraction layer of said one or more second layers ischosen from a group comprising SiO, SiO₂, MgF₂ and siloxane polymers;optionally, the metallic layer is chosen from a group comprising Al, Ag,Rh, Pd, Cu, Au, Cr, Ti, Ni, nickel/gold alloys, chrome/gold alloys,silver/aluminum mixtures and combinations thereof; optionally, thedevice comprises a metal-oxide layer coupled to said first surface ofsaid light emitting portion wherein the metal-oxide layer comprises oneor more layers wherein at least the first layer has an index ofrefraction greater than 2 and an optical loss factor less than 0.2;optionally, the metal-oxide layer is chosen from a group comprisingmetal oxides, silicon carbide, GaN, Ta₂O₅, Nb₂O₅, TiO₂, AlInGaN basedsolid solutions and their non-stoichiometric mixtures, and wherein saidmetal-oxide layer portion has a predetermined shape and pattern;optionally, the metal-oxide layer comprises a first and second coatinglayer wherein the first coating layer is in contact with the lightemitting portion and has an index of refraction greater than 2 and anoptical loss factor less than 0.2 and the second coating layer portionhas three dimensional pattern chosen from a group consisting of ribs,cylinders, slots, polygon shaped ribs, triangular shaped ridges,hemispherical shaped mounds, horizontal cylindrical shaped ribs,cylinders, ellipsoids, hemispheres, rectilinear trenches, rectilinearsolids, cones, angled cylinders, angled hemispheres, angled ellipsoids,angled rectilinear trenches, angled solids and angled cones and whereinelement to element spacing may be uniform or not; optionally, thesubstrate is chosen from a group comprising sapphire, silicon carbide,GaN, and silicon.

Foregoing described embodiments of the invention are provided asillustrations and descriptions. They are not intended to limit theinvention to precise form described. In particular, it is contemplatedthat functional implementation of invention described herein may beimplemented equivalently. Alternative construction techniques andprocesses are apparent to one knowledgeable with integrated circuit,packaging and MEMS technology. Other variations and embodiments arepossible in light of above teachings, and it is thus intended that thescope of invention not be limited by this Detailed Description, butrather by Claims following.

1. A device capable of emitting light about a predetermined wavelengthin response to an applied electric current comprising: a substratecomprising first and second surfaces; a light emitting portioncomprising a semiconductor material and first and second surfaceswherein the light is emitted from the first and second surfaces and thesecond surface is substantially coupled to the first surface of thesubstrate; a first layer coupled to the second surface of the substratecomprising an optically transmissive, dielectric layer with a refractiveindex less than the refractive index of the substrate and of a thicknessgreater than one-quarter wavelength of the predetermined wavelengthdivided by the index of refraction of the optically transmissivedielectric layer; one or more second layers coupled to the first layerwherein each second layer comprises a first dielectric layer ofhigh-index of refraction and a second dielectric layer of low-index ofrefraction wherein the first dielectric layer is of a thickness aboutmλ/4n_(H), and the second dielectric layer is of a thickness aboutkλ/4n_(L), where m and k are odd integers, λ is the predeterminednominal wavelength in air, n_(H) is the refractive index of thehigh-index of refraction dielectric layer and n_(L) is the refractiveindex of the low-index of refraction dielectric layer; and a metalliclayer coupled to the one or more second layers; wherein the reflectivityof the metallic layer to the predetermined wavelength is greater thanabout 50 percent.
 2. The device of claim 1 wherein said metallic layercomprises at least three layers comprising: a first layer comprisingsaid metallic layer; a second layer comprising a diffusion barrier; anda third layer of a solderable material; wherein elements of thesolderable material are prevented from reaching said metallic layer bythe second layer.
 3. The device of claim 1 wherein said opticallytransmissive, dielectric layer is chosen from a group consisting ofsilicon dioxide, silicon monoxide, MgF₂ and siloxane polymers.
 4. Thedevice of claim 1 wherein said high-index of refraction layer of saidone or more second layers is chosen from a group consisting of titaniumdioxide (TiO₂), Ti₃O₅, Ti₂O₃, TiO, [ZrO₂+TiO₂ZrO₂Nb₂O₅], CeO₂, ZnS,Al₂O₃, niobium pentoxide (Nb₂O₅), tantalum pentoxide (Ta₂O₅) andsiloxane polymers and said low-index of refraction layer of said one ormore second layers is chosen from a group comprising SiO, SiO₂, MgF₂ andsiloxane polymers.
 5. The device of claim 1 wherein said metallic layeris chosen from a group consisting of Al, Ag, Rh, Pd, Cu, Au, Cr, Ti, Ni,nickel/gold alloys, chrome/gold alloys, silver/aluminum mixtures andcombinations thereof.
 6. The device of claim 1 further comprising ametal-oxide layer coupled to said first surface of said light emittingportion wherein the metal-oxide layer comprises a first layer with anindex of refraction greater than 2 and an optical loss factor less than0.2.
 7. The device of claim 6 wherein said metal-oxide layer is chosenfrom a group consisting of metal oxides, silicon carbide, GaN, Ta₂O₅,Nb₂O₅, TiO₂, AlInGaN based solid solutions and their non-stoichiometricmixtures, and wherein said metal-oxide layer portion has a predeterminedshape and pattern.
 8. The device of claim 6 wherein said metal-oxidelayer further comprises a second coating layer wherein the secondcoating layer portion has a three dimensional pattern chosen from agroup consisting of ribs, cylinders, slots, polygon shaped ribs,triangular shaped ridges, hemispherical shaped mounds, horizontalcylindrical shaped ribs, cylinders, ellipsoids, hemispheres, rectilineartrenches, rectilinear solids, cones, angled cylinders, angledhemispheres, angled ellipsoids, angled rectilinear trenches, angledsolids and angled cones and wherein element to element spacing may beuniform or not.
 9. A device capable of emitting light about apredetermined wavelength in response to an applied electric currentcomprising: a substrate comprising first and second surfaces; a lightemitting portion comprising a semiconductor material and first andsecond surfaces wherein the light is emitted from the first and secondsurfaces and the second surface is substantially coupled to the firstsurface of the substrate; a first layer coupled to the second surface ofthe substrate comprising an optically transmissive, dielectric layerwith a refractive index less than the refractive index of the substrateand of a thickness greater than one-quarter wavelength of thepredetermined wavelength divided by the index of refraction of theoptically transmissive dielectric layer; one or more second layerscoupled to the first layer wherein each second layer comprises a firstdielectric layer of high-index of refraction and a second dielectriclayer of low-index of refraction wherein the first dielectric layer isof a thickness about mλ/4n_(H), and the second dielectric layer is of athickness about kλ/4n_(L), where m and k are odd integers, λ is thepredetermined nominal wavelength in air, n_(H) is the refractive indexof the high-index of refraction dielectric layer and n_(L) is therefractive index of the low-index of refraction dielectric layer; ametal-oxide layer coupled to said first surface of the light emittingportion wherein the metal-oxide layer comprises a first layer with anindex of refraction greater than 2 and an optical loss factor less than0.2; and a metallic layer coupled to the one or more second layers;wherein the reflectivity of the metallic layer to the predeterminedwavelength is greater than about 50 percent.
 10. The device of claim 9wherein said metal-oxide layer further comprises a second coating layerwherein the second coating layer portion has a three dimensional patternchosen from a group consisting of ribs, cylinders, slots, polygon shapedribs, triangular shaped ridges, hemispherical shaped mounds, horizontalcylindrical shaped ribs, ellipsoids, hemispheres, rectilinear trenches,rectilinear solids, cones, angled cylinders, angled hemispheres, angledellipsoids, angled rectilinear trenches, angled solids and angled conesand wherein element to element spacing may be uniform or not.